Pocketed four-link front suspension

Abstract

A suspension system for a motor vehicle wherein an upper control arm on each side of the vehicle is located in an aperture within the vehicle frame and operably connected to a front axle. Each upper control arm is pivotably connected to the frame and is capable of rotating into the aperture in response to a force generated by contact of its respective wheel with an irregularity in the road surface during the operation of the motor vehicle. As the upper control arms are placed within the frame rails, interference between the control arms and other components located in the engine compartment is substantially eliminated. The substantial elimination of this interference reduces the design effort and lead time associated with the development of the vehicle frame and suspension system as well as integrating the engine into the vehicle. The ability to assemble and service the vehicle are likewise improved through the elimination of the entanglement between suspension components and engine components. Additionally, placement of the upper control arms within the frame rails serves to isolate the control arms from the elevated temperatures of the engine compartment.

I claim: 
     
       1. A suspension system for attachment with an axle, the suspension system comprising: a frame structure having a longitudinal side rail with a longitudinal aperture formed therein; and   a control arm assembly having first and second end portions, the first end portion adapted to be pivotably coupled to the axle, the second end portion pivotably coupled to the longitudinal side rail, the control arm assembly being pivotable about the second end portion between a first position wherein the first end portion extends at least partially from the longitudinal aperture and a second position wherein the first end portion is completely disposed within the longitudinal aperture.   
     
     
       2. The suspension system of claim 1, wherein the second end portion of the control arm assembly is disposed within the longitudinal aperture. 
     
     
       3. The suspension system of claim 2, wherein the side rail includes a pair of reinforcements, each one of the pair of reinforcements disposed within the longitudinal aperture and fixedly coupled to one of a pair of lateral side members of the side rail, the second end portion of the control arm assembly positioned between the pair of reinforcements. 
     
     
       4. The suspension system of claim 3, wherein each one of the pair of reinforcements has a frusto-conical shape. 
     
     
       5. The suspension system of claim 1, wherein each of the first and second end portions includes a bore that is perpendicular to a longitudinal axis of the control arm assembly. 
     
     
       6. The suspension system of claim 5, wherein the control arm assembly further includes a plurality of resilient bushings, the resilient bushings disposed in each of the bores in the first and second end portions. 
     
     
       7. The suspension system of claim 1, wherein the control arm assembly includes a control arm having a tubular arm member and a pair of tubular end members, the arm member having a longitudinal axis, the end member coupled to each end of the arm member, the end members oriented to the arm member such that the longitudinal axis of the end members is perpendicular to the longitudinal axis of the arm member. 
     
     
       8. A vehicle comprising: an axle assembly having an axle and a wheel;   a frame structure having a longitudinal side rail with a longitudinal aperture formed therein; and   a control arm assembly having first and second end portions, the first end portion pivotably coupled to the axle, the second end portion pivotably coupled to the longitudinal side rail, the control arm assembly being pivotable about the second end portion between a first position wherein the first end portion extends at least partially from the longitudinal aperture and a second position wherein the first end portion is completely disposed within the longitudinal aperture.   
     
     
       9. The vehicle of claim 8, wherein the second end portion of the control arm assembly is disposed within the longitudinal aperture. 
     
     
       10. The vehicle of claim 9, wherein the side rail includes a pair of reinforcements, each one of the pair of reinforcements disposed within the longitudinal aperture and fixedly coupled to one of a pair of lateral side members of the side rail, the second end portion of the control arm assembly positioned between the pair of reinforcements. 
     
     
       11. The vehicle of claim 10, wherein each one of the pair of reinforcements has a frusto-conical shape. 
     
     
       12. The vehicle of claim 8, wherein each of the first and second end portions includes a bore that is perpendicular to a longitudinal axis of the control arm assembly. 
     
     
       13. The vehicle of claim 12, wherein the control arm assembly further includes a plurality of resilient bushings, the resilient bushings disposed in each of the bores in the first and second end portions. 
     
     
       14. The vehicle of claim 8, wherein the control arm assembly includes a control arm having a tubular arm member and a pair of tubular end members, the arm member having a longitudinal axis, the end member coupled to each end of the arm member, the end members oriented to the arm member such that the longitudinal axis of the end members is perpendicular to the longitudinal axis of the arm member. 
     
     
       15. A suspension system for attachment with an axle, the suspension system comprising: a frame structure having a longitudinal side rail with a longitudinal aperture formed therein; and   a control arm assembly having first and second end portions, the first end portion adapted to be pivotably coupled to the axle, the second end portion disposed in the longitudinal aperture and pivotably coupled to the longitudinal side rail, the control arm assembly being pivotable about the second end portion between a first position wherein the first end portion extends at least partially from the longitudinal aperture and a second position wherein the first end portion is completely disposed within the longitudinal aperture.   
     
     
       16. The suspension system of claim 15, wherein the side rail includes a pair of reinforcements, each one of the pair of reinforcements disposed within the longitudinal aperture and fixedly coupled to one of a pair of lateral side members of the side rail, the second end portion of the control arm assembly positioned between the pair of reinforcements. 
     
     
       17. The suspension system of claim 16, wherein each one of the pair of reinforcements has a frusto-conical shape. 
     
     
       18. The suspension system of claim 15, wherein each of the first and second end portions includes a bore that is perpendicular to a longitudinal axis of the control arm assembly. 
     
     
       19. The suspension system of claim 18, wherein the control arm assembly further includes a plurality of resilient bushings, the resilient bushings disposed in each of the bores in the first and second end portions. 
     
     
       20. The suspension system of claim 15, wherein the control arm assembly includes a control arm having a tubular arm member and a pair of tubular end members, the arm member having a longitudinal axis, the end member coupled to each end of the arm member, the end members oriented to the arm member such that the longitudinal axis of the end members is perpendicular to the longitudinal axis of the arm member.